Fiber enforced thin brick sheet and process

ABSTRACT

A fiber enforced sheet for use as a wall or floor covering which comprises of adhered thin bricks bonded to a fiber-reinforced, backing layer. Thin brick is adhered to the fiber enforced sheet. The fiber enforced backing increases strength and rigidity to the thin brick during handling, and installation permits the thin bricks to be adhered to proper specification and spacing to be cut using ordinary tile or thin brick tools.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to fabricated thin brick sheets for use as wallor floor coverings and a process for manufacturing such sheets. Theinvention is a veneer, one layer of which comprises of an array of gluedor adhesive applied thin bricks.

2. The Prior Art

Thin brick has long been a highly desired backing material for walls andfloors, for interior and exterior, and the like. It is attractive,durable, waterproof, and fireproof. Thin bricks are available in a widevariety of sizes, shapes, colors, patterns, textures, and surfacefinishes. They are uniquely suited to a variety of applications rangingfrom decorative accents in the homes to complete commercial exteriorfinishes.

Thin brick per se is relatively inexpensive, being made essentially fromclay minerals fired at high temperature. Not so its installation. Theconventional construction of a thin brick wall, for example, begins withthe installation of metal lath over a vapor barrier secured sheathing.Next, a scratch coat of mortar is applied to the lath followed by anaccurately leveled mortar bed for the thin brick. Should the scratchcoat be uneven, a separate, additional leveling layer of mortar may berequired. When using adhesive brick are set one by one then groutedusing mortar applied between thin brick. Individual thin bricks must becut using special equipment and tools to fit them to spaces requiringless than a full thin brick or to fit them around fixtures and the like.

Thin brick setting is a skilled occupation, commanding high wages. Thelevel of skill required, and the time-consuming nature of conventionalthin brick installation render the process very expensive.Unfortunately, due to the high cost of thin brick installation, somebuilders have attempted installation shortcuts in a misguided effort tosave money. Improper installation techniques frequently result inexpensive repairs for the homeowner or general contractor.

Given this situation, it is not surprising to find a number of proposedsolutions to the problem in the prior art. The concept of aprefabricated thin brick sheet which would not require any thin bricksetting at the installation site has long been considered. However, thethin brick sheets previously described have all proved unsatisfactoryfor reasons such as insufficient strength, excessive weight, complexityof installation, and high labor cost. And none have met with commercialsuccess to any significant extent.

Thus, it will be appreciated that the prefabricated thin brick sheetsknown in the art prior to this disclosure all relied on a core part,commonly of steel, plastic, foam, or a relatively thick backing layer toimpart some measure of structural strength and rigidity to the sheets.These cores substantially increase the thickness of the sheets, and thisin turn necessitates special mounting hardware for installation.

SUMMARY OF THE MENTION

The present invention comprises a thin, lightweight thin brick sheetwhich greatly simplifies and reduces the cost of installing thin brickwalls, floors, and the like. The invention further comprises a method ofmaking such a sheet and or installation.

The thin brick sheets of the invention include a plurality of thinbricks pre-assembled and mounted on a fiber enforced sheet. The spacesbetween the thin bricks are filled with grout to seal these spacesagainst moisture, etc. The term “grout” should be understood to includeboth the conventional thin, cementitious mortar used for filling jointsin masonry as well as chemicals that solidify, such as polyurethanes,room temperature vulcanizing silicones, other elastomers, plastics, andthe like. The sheets normally feature a regular pattern of substantiallyrectangular thin bricks in a side-by-side, laterally spaced rectangulararray; however, a wide variety of thin brick shapes and trim pieces arecontemplated.

The thin bricks of the invention are preferably thinner and lighter thancommon bricks. Thus, the thin bricks will generally be greater than0.125 inch thick, and less then 3 inches. The light weight of the thinbricks makes it possible for relatively large sheets of such thin bricksto be assembled and handled with comparative ease. The fiber enforcedsheet may be made of a variety of materials. The sheets themselves willnormally be flexible, but it is important that they be substantiallynon-stretchable. This quality is important because the backing andbacking sheets on each thin brick sheet co-act to render the sheet rigidenough to be readily handled and worked.

Working of the thin brick sheets for example, may include cutting ordrilling with tools such as razor knifes, table saws, and the like.After the thin bricks are adhered the sheets can then be cut betweenbricks using just a razor knife. This enables such working to be carriedout with very little breaking, chipping, or other damage to the thinbrick elements.

Applying thin brick sheets over exterior require cementitious adhesivesealing all seams and applying a roll on water barrier following allbuilding codes. When applying thin brick sheets over interior, athinset, mastic or equivalent will be required.

It will be apparent that the sheets be strong, substantiallynon-stretchable, substantially water-resistant, chemically stable, andcapable of being bonded to the thin bricks as well as to plaster, wood,cement, block, drywall sheets [gypsum board; sheetrock], etc. withconventional construction adhesives. As mentioned above, wovenfiberglass fabric is an especially preferred component of the backingsheets; however, other fabrics or reinforcing agents considered suitableinclude polyester, graphite, aramid, or carbon fibers, or anycombination thereof. Especially preferred is a fiberglass combination.

Synthetic adhesives suitable for impregnating the backing sheets includeunsaturated fiberglass, phenolic, epoxy, and silicone adhesives.

In general, the adhesives should possess the same generalcharacteristics as the backing sheets. The cured adhesive should bestrong, substantially non-stretchable, substantially impervious tomoisture, function as an adhesive to bond the back surfaces of the thinbricks to the sheet, and be capable of being bonded to common wallsurfaces and the like with conventional construction adhesives such asthin set or mastic and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 Is a cross-sectional view of fiber enforced thin brick sheets ofthe said invention.

FIG. 2 Cut thru order of fiber enforced thin brick process.

FIG. 3 Is a cross-sectional view of corner brick using fiber enforcedthin brick sheets in the process of the said invention.

FIG. 4 View of an example layout of the corner thin brick sheets of saidinvention showing application arrangement and edges of such a sheet.

DETAILED DESCRIPTION OF THE DRAWINGS

The invention will best be understood by referring to the drawings.

FIG. 1 shows a portion of a thin brick sheet in cross section.Individual thin brick elements (5) are supported by adhesive (6) on afiber-reinforced backing layer (7). Anti-adhesive paper on back of thinbrick sheets for separation and adhesive release (8).

FIG. 2 schematically it a cut thru fabricated thin brick sheets. Thinlayer of anti-adhesive paper to prevent bonding of the backing layeradhesive (9). Reinforcing fabric (10) for the backing layer. Adhesive ata high temperature is then impregnated or applied to either brick orfiber-reinforced backing layer (11). Individual thin brick elements(12).

FIG. 3 schematically illustrates corner thin brick sheets. Thin layer ofanti-adhesive paper to prevent bonding of the backing layer adhesivethat is curved in the same position of a typical thin brick corner (13).Reinforced fabric sheet that is curved in the same position of a typicalthin brick corner (14). Adhesive at a high temperature is thenimpregnated or applied to either corner brick or fiber-reinforcedbacking layer (15). Thin corner brick positioner (16) helps in theproper spacing and alignment process.

FIG. 4 shows in detail the layout of an optional embodiment of the thinbrick sheets and corner sheets of the present invention. Corner sheetsare typically applied first (17) were brick are placed opposite of eachother. The thin bricks are staggered in typical brick patterns (18) andfiber-reinforced backing layer extends beyond the thin brick elements onone edge of the sheet (19), while on the opposite edge the thin brickelements overhang the fiber-reinforced backing layer by an equaldistance (20). This permits abutting thin brick sheets to be joinedtogether in such a way that the joint between bricks are the properspace to adjacent thin brick sheets.

SUMMARY

Alternatively, the sheets of the present invention may be manufacturedindividually in multiple sizes. Thin bricks are placed face down or faceup within the confines of a frame designed to hold the loose thin bricksin a rectangular array. Gaps are left between the edges of adjacent thinbricks to permit the subsequent insertion of grout as is well known inthe art.

Reinforcing fabric for the hacking layer is then placed over the exposedrear surfaces of the thin brick elements in the array. A adhesive isthen applied to the fabric first or brick first, saturating it andextending through it to contact the thin bricks or sheets. As theadhesive cures it bonds the backing layer to the thin bricks. Thisprocess may be accelerated by the application of heat to raise thetemperature of the adhesive/catalyst mixture thereby increasing its curerate.

When the adhesive of the backing layer has substantially cured, thehacking layer with the thin brick elements bonded to it is inverted,exposing the front face of the thin brick elements. Grout or mortarother suitable or alike material is applied to the spaces between thethin bricks.

In use, the thin brick sheets are mounted to conventional floor or wallsurfaces using construction adhesives of the type previously mentioned.

While one specific embodiment of the invention has been disclosedherein, it should be understood that this disclosure is made by way ofillustration rather than limitation. Numerous changes may be made bythose skilled in the art, particularly with reference to the dimensions,materials and configuration disclosed herein. Changes of this naturewould not depart from the spirit of the invention or the scope of theappended claims.

1-41. (canceled)
 42. A method of installing thin brick sheets,comprising: applying a first adhesive to a wall or floor surface; andapplying a thin brick sheet to the wall or floor surface, wherein thethin brick sheet comprises a backing layer and a plurality of thinbricks that are bonded to the backing layer via a second adhesive,wherein the backing layer defines a grid that comprises a plurality ofholes, and wherein the plurality of thin bricks are bonded to thebacking layer such that the first adhesive penetrates through theplurality of holes to hold the brick sheet to the wall or floor surface.43. The method of claim 42, wherein the backing layer isnon-stretchable.
 44. The method of claim 42, wherein the backing layercomprises at least one of fiberglass, polyester, graphite, aramid, orcarbon.
 45. The method of claim 44, wherein the backing layer comprisesfiberglass.
 46. The method of claim 42, wherein the plurality of bricksare adhered to the backing layer in a running bond pattern or a stackbond pattern.
 47. The method of claim 46, wherein the plurality ofbricks are adhered to the backing layer in a stack bond pattern.
 48. Themethod of claim 42, wherein the adhesive penetrates through a pluralityof holes disposed behind the plurality of thin bricks to bond the thinbricks to the wall or floor surface.
 49. The method of claim 42, whereinthe plurality of thin bricks comprise one or more of clay bricks, castbricks, or wire cut bricks.
 50. The method of claim 42, wherein the thinbrick sheet consists of four rows of thin bricks.
 51. The method ofclaim 50, wherein the thin brick sheet consists of three thin bricks perrow.
 52. A method of installing thin brick sheets, comprising: applyinga first adhesive to a wall or floor surface; and applying a thin bricksheet to the wall or floor surface, wherein the thin brick sheetcomprises a backing layer and a plurality of thin bricks that are bondedto the backing layer via a second adhesive, wherein the backing layerdefines a grid that comprises a plurality of holes, and wherein theplurality of thin bricks are bonded to the backing layer such that thefirst adhesive penetrates through the plurality of holes to hold a rearsurface of the brick sheet to the wall or floor surface.
 53. The methodof claim 52, wherein the backing layer is non-stretchable.
 54. Themethod of claim 52, wherein the backing layer comprises at least one offiberglass, polyester, graphite, aramid, or carbon.
 55. The method ofclaim 54, wherein the backing layer comprises fiberglass.
 56. The methodof claim 52, wherein the adhesive penetrates through a plurality ofholes disposed behind the plurality of thin bricks to bond the thinbricks to the wall or floor surface.
 57. The method of claim 52, whereinthe plurality of thin bricks comprise one or more of clay bricks, castbricks, or wire cut bricks.
 58. The method of claim 52, wherein the thinbrick sheet consists of four rows of thin bricks.
 59. The method ofclaim 58, wherein the thin brick sheet consists of three thin bricks perrow.
 60. A method of installing thin brick sheets, comprising: applyinga first adhesive to a wall or floor surface; and applying a thin bricksheet to the wall or floor surface, wherein the thin brick sheetcomprises a backing layer and a plurality of thin bricks that are bondedto the backing layer via a second adhesive, wherein the plurality ofthin bricks comprise one or more of clay bricks, cast bricks, or wirecut bricks, wherein the backing layer defines a grid that comprises aplurality of holes, wherein the plurality of thin bricks are bonded tothe backing layer such that the first adhesive penetrates through theplurality of holes to hold a rear surface of the brick sheet to the wallor floor surface, and wherein the thin brick sheet consists of four rowsof thin bricks.
 61. The method of claim 60, wherein the thin brick sheetconsists of three thin bricks per row.